Kaizen Basic Education: Created On February 2011

Kaizen Basic
Education
Created on February 2011
　　
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1.What is Kaizen?
　 The general meaning of Improvement (Kaizen) is to improve a thing that is in bad
condition. The term Improvement in the manufacturing industry has the meaning of
bottom up activities are carried out mainly by the factory workers.
Summary:
The activities of improving the production are to equip modifications, new tools and work to ensure
the safety and operational efficiency of a production error proofing all over the area and to prevent
problems related to quality production.
Improvement is often described as Kaizen nowadays. When the expansion of Japanese

manufacturing plants abroad, trainers were dispatched from Japan to teach the local staff. MIT
researchers became the centre of the strength of Japanese manufacturing in the 1980s. Mari
Hiroshi as well as overseas are one of the most important manufacturing industry in Japan.
Through such result, Kaizen became the world-wide word in the world.
In order to improve current facilities, quality of the machine and productivity,

Field side’s wisdom, quality and the activity of increasing productivity are done.
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1. What is Kaizen?
1. Production facilities that incorporate the wisdom, have a lead to others using the same
equipment.
2. By making modifications on their own to suppress large-scale investment rather

than just buying what you lack.
3. Improvement is not just working under the order of company but the characteristic of workers
changing things out of their own wisdom.
4. Employers support a lot of QC-circle activities. Moreover improvement is not finished once but
one after another, sustainability and continuity are important.
Multiply time
with money to
Effect get the effect.
Value of improvement ＝
Money×Time
Increasing the value without paying out money but using the wisdom to.
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2. The History of Kaizen
The management system of Toyata is the first to incorporate and utilize the wisdom of
the workers systematically to achieve achievements. The productivity in the
field side, changing of the work methods in order to improve the quality and the jigs are
used in any country and any era have been implemented with the immediate on-
site productivity without spending money and improve the quality.
　　 1. Sakichi Toyoda ・・・ ‘ Automation with A Human Touch’
　　　 2. Kiichiro Toyoda ・・・ Just-in-time (J.I.T)
　　　 3. Taiichi Ohno ・・・ Systemization of the production of Toyata
Toyata is the first to incorporate and utilize the wisdom of the workers

systematically to achieve achievements.
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Reference 1. History and philosophy of Toyota Production System
　　 Sakichi Toyoda Kiichiro Toyoda 　 Taiichi Ohno
(Inventor) (Founder) (Executive Vice President )
‘Automation with A Human

Touch’ ‘JUST －IN －TIME’ Introduction of ‘Toyota
"What is needed, when
needed, as needed!" Production System’
“Machine stops itself when a
problem occurs” 　 Year 1942
“Elimination of waste”
Install a device to stop the machine to

stop automatically when abnormality Passenger Type AA (mass-produced
occurs, then investigate the cause. passenger car type A1) production
starts. 　　 Year 1936
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Reference2. The Philosophy of Toyata Production
• The success of the Toyota Production System is not just because of the tools
of production management such as ‘Kanban’, ‘Kaizen’ etc., it is a culture or a
system that can cultivate ideas and make good products day and night at the
site by the carpenters.
A culture or a system of cultivating ideas.
• Persist in on-the-spot decision-

making TOP management • The mechanic of lighting up Kaizen
• Process-oriented principles. (The desire.
changing of results depends on the
luck by the time.) • The use of automation.
This steady is the practice of maximum effort and because the results are
influenced by the good or bad luck so do not be glad and sad by turns.
(Process-oriented principles)
The Toyata Production System is a transmission of the good Japanese
traditions nowadays.
　　　　　 “ The sincerity and humanity itself is impossible without incident.

However, the lack of them destroys everything.”
　 Peter Drucker 6
Reference 3. The Kanban System
From the beginning until the last process,
take only the required amount of the
required items when required. Then, the
earlier manufacturing process is to supply
only the amount of production which was
taken over. In this way, the Kanban
method prevents over process while being
a tool of putting the overall just-in-time into
practice.
　　 1. The origin of ‘one piece flow’

manufacturing
2. Following with the take-back
process
　　 3. Zero inventory
　　 4. ‘Leveling work’ → Obey the
cycle time
　　 5. Do not make it so fast.
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Reference 　 4
“Automation with A Human Touch”
1. Immediately stops the line when poor
response occurs.
2. It brings confusions to customers if

a product is produced without handling the real
cause.
3. “Automation with a Human Touch” is not

about "Automation" but to attach humans’
wisdom onto the machine so it will not shut off
automatically.
4. Keep asking the question ‘Why?’ even for 5 or

10 times and is necessary to have a line of does
not want something bad to occur for the second
time.
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Reference 　 5. Muda (Waste) Elimination
‘Treasure things’ and ‘the thinking of do not waste’ are the
origin of eliminating muda.
1. Muda of processing 2. Muda of inventory 3. Muda of overproduction
4. Muda of waiting 5. Muda of repair/rejects 6. Muda of transport
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Reference 6.The Mind of Toyota's manufacturing
"In a company when there is no race to get each

person to add their good ideas to the work they do, I
think this ruins people. Your improvements make the
job easier for you, and give you time to make further
improvements. Unlike in the [Charlie] Chaplin movie
where people are treated as parts of a machine, the
ability to 'add your creative ideas and changes to
your own work' is what makes it possible to do work
that is worthy of humans."
　　　　　
Taiichi Ohno
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3. The Kaizen Philosophy
The world is constantly changing. Therefore, corporations as well as the people are
changing, if countermeasures are not practiced, one cannot survive.
At first, explore the changes that are under the constraints.
There is an infinite ways of changing but in able to survive, change is finite. However, no
one knows what is the BEST changing. Possibility for changes in BEST are hidden from
the changes in non-BEST.
The valuation of whether it is BEST or not is, because the decision is made by the external
world (customers), the decision itself cannot determine and be concluded.
When the evaluation of the outside world is good, then that is the good one.
Therefore, the first thing we need to do is to take action of the changes.
Results will be known if action is taken, the next action can be taken if the results is
analyzed.
Countermeasure 1: Wear a coat. Select the BEST option

Getting cold. Countermeasure 2: Use the heating system. to fit the constraints.
Countermeasure3: Move to a warmer place.
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Taking a serious view of the results or the process?
For everything, it is not a big achievement if something successes
according to the plan in our head. Because such a thing has always
already been implemented..
The probability of successful is low, the thing no one wants to do,

no one implements it and therefore, there is a value of trying.
　 Then try to verify why failures occurred.
Never give up and key to success is in it.
“Our greatest weakness lies in giving up. The most certain

way to succeed is always to try just one more time.” 　　
Thomas Edison
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According to the global changes, the method of work has
to correspond in accordance with the corresponding reality.
At first, grope for the correspondence in the constraints.
・New technology
development
・Groundbreaking
material development Reality and Kaizen
constraint
・Moves of competitors corresponding
・Costumer needs
・Legal regulations
A task is defined as a work to achieve a given objective. While Kaizen is

defined as a better way to achieve the business objectives and make
changes to a method.
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4 ． How to proceed Kaizen?
Organization. Management. Cogitation.
1) Organization: The continuity of developing the entire Kaizen
organization.
・ Membership 　
　　　　　　　　・ Rules and regulations are made.
2) Management: Make an approachment and a mechanism to keep the

management system on track and the activation of Kaizen
activities.
　　　　　　　・ Select and train a leader.
3) Cogitation ： Explain and make the employees consent to the definition of

Kaizen.
・ Kaizen education
Organization is set up in order to continue the promotion system at the field level.
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4. How to proceed Kaizen?
Promote Kaizen to employees.
1. The way of thinking ：Understand the meaning of Kaizen and
urge the participation of Kaizen activities.
2. Enthusiasm ：Set a notice board and premium for those who
are actively involved.
3. Education ：Educate the technology of efficiency
improvement and methods.
Thinking
Education Enthusiasm
Employees’ opinions, enthusiasm and education are necessary.

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4. How to proceed Kaizen?
Kaizen Implementation
1. Immediate implementation. Immediate action:
　　 If there is any problem, apply Kaizen on the spot.
There are Kaizen chances if problems occurred especially when Start at once
the problems only occur occasionally.
Analyze the situation on the spot and investigate the problem.
2. Do not waste time:

　　 Do not conduct special meetings but instead proceed Kaizen.
Seek advice from supervisors and seniors if there is something Time 　 is 　 Money
to consult and confirm.
3. Do not spend money:

　 The resolution of trouble cannot be handled by money.
The thinking of whether one can access alternatively cheap and Don’t Spend Money
available for carrying out present item as well as commercial item.
4. Suggestion from others:

Seek suggestions from supervisors, seniors as well as
managers from other departments. Two heads are better than one
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5. Kaizen & Innovation
Innovation
The innovation type of revolution of the world leads to a contribution in development and
spend a lot of time and money on invention. Also again, there are many developed,
invented and copied items, profit as well as the members who are in charge of it comes to
only have a small amount and it often does not occur.
Characteristics:
1. It needs an enormous cost.
2. A long-term studies is needed.
3. Miscellanies do not occur frequently.
4. Easy to be imitated.
5. Planned implementation. (Analysis of present state, countermeasure,
affirmation, evaluation)
Invention of light bulb, print technology, airplane…
Invention of internet, e-mail, Messenger…

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Invention of CD, personal computer, microwave…
Increasing The Productivity
Productivity can be improved by increasing the productivity which consumes a
lot of time and money and it includes the members and all the field workers.
Also, a good management system that is built is difficult to be
imitated by other companies.
Characteristics:
1. Huge sum of money and does not take time.
2. Possibility of educating the employees.
3. Can respond to daily problems.
4. Difficult to imitate.
5. Take actions immediately.
Kaizen is a system, there is no point in learning techniques

and their own individual cultures.
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Comparisons
Kaizen Innovation
Effect Long-term, continuous Short-term, dramatic
Time Fast response Development for a long time
Change A constant slow Sudden & explosive

Participation All Some elite
Approach Collectivism and systems Individualism idea
approach
Way Maintenance & Scrap & build
improvement
Benefit Function in low-growth Features of high-growth
economy economy
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The Type of Innovation
Ideal Innovation Pattern

Actual Innovation Pattern
Loss
management
Loss
management
Outbreak of
innovation
Loss
management Outbreak of
innovation
“The organization or the system is an organization (or a system) that is to be

finished begins to degenerate.” Parkinson’s law 20
5 ．Kaizen & Innovation
QC Management & Facilities Management
Ideal innovation pattern Loss

management
Reality innovation pattern
Loss
management
Outbreak of
innovation
Loss
management
Outbreak of
innovation
In order to reduce loss management, QC management and facilities

management are implemented to maintain and continue the status quo.
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5. Kaizen and Innovation
Kaizen
Ideal innovation pattern

Reality innovation pattern Kaizen
Kaizen pattern Loss
management
Kaizen
Loss
management
Outbreak of
innovation
Kaizen
Loss
management
Outbreak of
innovation
Kaizen is the better way to explore under restriction limits.

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6. Practical Kaizen System
What is Kaizen?
Kaizen is about the changing of the method of work without hassles, without
spending money and using the wisdom to make work easy, safe and fast.
Also, write down notes of Kaizen and doing recording is important.

If manifestation is being measured and communized with everyone is possible,
a new Kaizen is born.
Kaizen = Reality measures

Enforcement
• Without hassles
• Without spending money
• Using the wisdom
Communization Recording
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Implementation
• In order to promote Kaizen, the important thing is there must
be implementation.
• The traditional proposal system is going to be outdated in the
future. The idea of ‘I am the proposer. You are the conductor.
’ does not work in the coming years.
• Try to practice it if you have any idea. If the idea is not good,
rethink and try again.
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of Record
1. Record the carried out Kaizen activity.

2. Content?
3. Effect?
4. The remaining challenges.
Start with the recorded and datalysed work.

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Communization
1. Contact the other departments related to the implementation,

discuss and communize the problem.
2. Provide education to the other departments.
3. Pose and review the problems.
Discuss with friends & ‘Databaselized’, education

superior authorities materials
Verification of
Kaizen types Implement effectiveness
Communization
Survey about IT & Provides information to other

other departments departments
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7. The Real Kaizen
The Formula of Kaizen Value
【 Standardization of the Pantograph Wear 】
Overhead wires stretched diagonally in order to reduce the wear of

the pantograph on the train and the contact part with overhead wires.
Pantograph
Trac
k
Direction of movement
Aerial
wiring
Trac
k
• Does not take time.

V = Effect ÷(Money ×Time) • Does not need money.
• Does not trouble. 27
7. The Real Kaizen
Simple Is The Best
1. If the work goes complicated, the mistakes will increase.
2. Consider the current situation and its original purpose of the
work and determine if there is no waste.
3. Consider whether there are better ways or not.
There are ways to achieve various objectives

but select the best one according to the present
state!
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7. The Real Kaizen
Eliminate The Unnecessary Works
1. To discern the necessary and unnecessary works. 　
2. Eliminate the unnecessary works to improve.
3. Focus on the primarily necessary work.
4. Attempt to improve the productivity and quality.
Firstly, eliminate the unnecessary work at the beginning!

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8. Standards of Kaizen
The Know-How of Kaizen
『 Stop 』
　・ Stop wasting
　・ Stop the unnecessary
　・ Stop the excessive
『 Reduce 』 : Abolition ⇒ Reduce
『 Add 』　
　・ Change the point of view.
　・ Change the procedures and methods.
　・ Replace the materials and components.
　・ Change crisis into opportunity.
　・ Return to the origin o basics.
　　　
Learn the standards of Kaizen and practice them

at the site. 30
　 Two Types of Problems
Unclear
Not enough
Unsafe
Uncomfortable
No ways
Tools are hard to find

Hard to place
Hard to be seen
Hard to grip
There are only 2 problems: 『 No 』　 and 『 Hard to~ 』 .

Therefore, there are only 2 measures: 『 ~tion 』　 and 『 Easy of~ 』 .
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The Two Measures
Clarification
Of sufficient
Securing
Of sound
Tools are easy to find

Easy to place
Easy to be seen
Easy to grip
The only 2 measures : 『 Of~ 』 and 『 Easy to~ 』 .

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Embodiment?
Definite plan ：
Make it transparent.
Change the direction.
Change the position.
Practice, take immediate action and put in habit on repeating asking the
question why and find a better way to reification.
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Visualization
Make it larger.
Make it visible.
Visualization
　 Make it brighter.
Plans Kaizen in order to find the problems easily.

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Visualization: Specific examples
1. Make it larger
2. Make it visible
3. Make it brighter
Visualize the small problems earlier in order to avoid the occurrence

of the big problems.
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Stationarized. Regularized. Stylized.
『 Issue 』
Problems of
irregular, etc. Must be adjusted
uneven
『 Kaizen Implementation 』
No adjustment
○-lized
needed
It consumes excessive time to fix the irregular pieces separately.

Fixing is not needed if stationarized, regularized and stylized are done.
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~ized: Specific Examples
1. Stylized: Memo of phone messages
Omission is not forgotten once you
have completed the necessary items
prepared beforehand in stylized form.
2. Stationarized: Tool board

Decide where to place and eliminate the
waste of searching.
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『 Issue 』
~ tion
Duplication, repetition and Extra effort needed
other problems
『 Kaizen
Implementation 』
Does not require extra
~tion effort
「Diversification 」
Share the duplicated collaboration part of elements and conditions in

advance. Strengthen the diversification according to the situation of Identity
things. However, there is an incompatibility in the mere diversification
of the scattered and mixed. The basic part is to plan the Sharing Compatibility
collaboration and demonstrate the unique synergy.

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Common in-: Specific Examples
1. Communization: Caliber of the guns & bullets
Decides if the diameter of a pre-caliber and the
bullets are compatible.
Musket
2. Collaboration: Basic PC software

Models, manufacturer and the data can be
collaborated.
PC OS
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『 Issue 』
Centralized
Simultaneous occurrence
of common
tasks with huge Wasted effort
organization needed
『 Kaizen Implementation 』
Centralized No wasted needed
The duplicate of an element will be a complicated mess.

For example, a huge waste is occurred when the size of an A B
organization is expanding and it collects similar data and Centralized
does the same thing as other departments. The waste of overlap
duplication can be omitted if "unify or centralize" is done.
C
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Of~ : Specific Examples
1. List of ~ : Checklist
To list multiple items, check the waste to
prevent leakage.
2. Centralization:
Centralized the printing of the label,
expiry date and bar code label of the
product to reduce working process.
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9. Education of Kaizen Ability
1. Education of employees and administrators are included.
2. Kaizen leadership education and training.
3. Learn from other departments:

Lecturer from other department 、 other plant tour
4. Create case studies and information about Kaizen

　 (Self study regarding to DVD and server usually.)
“To send the people to battle without teaching them is to abandon them.”
　　　　　　　　　　　　　　　　　　　　　　　　　 Confuciu
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Example of a Tabulation Plan
In April May June July August Septem
Items charge ber
Field education Kaizen 2nd 2nd 2nd 2nd 2nd 2nd
Wednesda Wednesda Wednesda Wednesday Wednesday Wednesda
leader y y y y
Kaizen leadership Other 3rd Friday 3rd Friday

department
training
Director education Other 20th of May 20th of July
department
Other plant tour Kaizen 5th May 5th August

leader
Lecture and All Mid of

June
education from
other departments
Each participants create a Kaizen education plan. 　

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Learn from others
• Learn information from other jobs and industries.
• For this, learn it with the attitude of humble and obedient.
• Do not learn anything from arrogance.
• It is necessary to be aware of the problems.
“The master said: “ When I walk along with two others, they may
serve me as my teachers. I will select their good qualities and
follow them, their bad qualities and avoid them.”
Confucius
　　　　　　　　　
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~ Education program ~
Education of Regular External Education
entering a education
company • External education
• Kaizen practical course
courses
Entering a
company
• Kaizen basic Professional • Other plant tour

courses course
• Presentation
• Kaizen basic 1) QC method
practises
2) Measuring
instruments
3) Equipment
maintenance
4) IE
5) Conserve
energy
6) Safety
7)PC ・IT 活用
Provides mental and technical education in order to improve the motivation and skills. 45
Reference Valuation & Qualifications
Case
Beginner Intermediate Advance Instructor

Course & Test Attend the Attend the Attend the Attend the
basic course intermediate advance course instructor course
and pass the course and and pass the and pass the test.
test. pass the test. test.
Practical Practical Practical Practical More than 10

suggestion suggestion suggestion educated
More than 100 More than 300 More than 500 beginners
Valuation Compensation: Compensation: Compensation: Compensation:

X million ¥ X million ¥ X million ¥ X million ¥
Increase the staffs’ motivation by introducing a licensing system and judicialized the valuations.
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Kaizen Collection of
Cases
　　
Created of February 2011
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1. Kaizen example: Boxing
Present condition
Boxing heavy products.
Issue: Arms are tired.
Traditional thinking:
　　　　　　 1. Get used to it very soon at
first.
　　　　　　 2. Try your best spirit!
　　　　　　 3. There is no enjoyable job!
Nothing perfects come into existence from the maintenance of the status quo.
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Of not in pain.
Why?
Issue: The arms are in pain. Why?
Why?
Arms are in in pain? Why?
1. No strength. - Suggestion: Muscle-building
2. Heavy products. - Suggestion: Make them light.
3. Lifting - Suggestion: Make them do not need to be lifted.
Make them do not need to be lifted.

1. Aiming of entering it on the top of the box.
Load
2. Aiming of exceeding the height of the box.
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Kaizen approach 1
1. Slide into the box horizontally. 2. Drop from the top.
Topic: Hard to do.
Topic: Worry for the impact of falling.
The approach of Kaizen is to find the optimal way in the innumerable constraints. 50

Kaizen approach 2
1. Side slope into the box. 2. Lay a cushion on the bottom of the box.
Topic: The cushions

cost.
It does not cost if it can be

Cushion
responded immediately.
Find the most suitable one out of the constraints! 51

Kaizen approach 3
Change the work order.
Assemble the boxes, after that do not place the goods
into the box but assembles the products when the box is
plane.
It is better to assemble the products than not taken the empty space
reasonably before keeping the boxes planed as it is.
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2. Kaizen example: Airborne Dust
Rationalize the work and settlement to avoid airborne
dust caused by machining work.
Consider the steps of operating before implementing the operation.
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3. Kaizen example: Cup Noodles
Issue: Frequent damage of the noodles in the process of inserting
noodles into the cups.
Damaged
noodles
Remove the broken pieces of the noodles during the process of putting the noodles into the cup. 54
4. Kaizen Example of Visualization ①
Human’s vision is the most developed among the five senses,
most of the information is getting through the eyes.
Before Kaizen After Kaizen

Forget to turn the air-conditioner off. Attach the ribbon to the air outlet.
Cannot confirm with the Can confirm with the eyes.

eyes.
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5. Kaizen Example of Visualization ②

Forget to close the tap occurs. Change it to lever.
Close
Open Close Open
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6. Kaizen Example of Visualization ③

Forget ordering occurs. Turn the order form over once
an order has made.
Order form Order
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7. Kaizen Example of Visualization ④

The coffee has not served yet in an Prepare the spoon and plate
order of a set of lunch and a cup of beforehand for the set served with
coffee. the coffee.
Order form 注文票
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8. Kaizen Example of Visualization ⑤

Cannot manage the stationary of the Implementation of the management
tools. board.
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9. Kaizen Example of Visualization ⑥

Does not know the screw is Tightening of the loose screw
loose. can be seen by eyes.
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10. Kaizen Example of Visualization ⑦

Does not know where had one Immediately return to the book’s
return the book. original position because there is a
mark on it.
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Kaizen- Present Guide
　　
Created on the February of Year 2011
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1. Practical Use of Current System
1. Information Age
　 There is an era of gathering and absorbing the knowledge one wants
efficiently. Innovation has mostly already been developed. It has become
official. After that, it is important how to leverage that knowledge to cords.
　　
Information
System Machine
Creative choice
Componentization
Utilizing the current system!! 63
2. Learning and Creative Choice
There are already ancestors from BC who came up with creative
thoughts. Things that created by geniuses like Socrates,
Plato, Buddha, etc. have already been documented in a book.
We can learn and select the thoughts which have been thought by
the ancestors. We now have a duty free and creative
editing to coding network simply by selecting from the
choices given.
““The master said: “ If a man keeps cherishing his old knowledge, so as

The master said: “ If a man keeps cherishing his old knowledge, so as
continually to be acquiring new, he may be a teacher to others.””
continually to be acquiring new, he may be a teacher to others.” ”
　　　　　　　　　　　　　　　　　　　　　　　　　　　　　 Confucius
　　　　　　　　　　　　　　　　　　　　　　　　　　　　　 Confucius
64
3. Turning Knowledge Into Wisdom
• Selection • Evaluate
• Try • Enquire
• Valuation • Actual field
Using the knowledge according to the field conditions.

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4. Kaizen’s Standard Tactics of
Application of ○
Use the features, services and tools efficiently.
The wrong idea of creating anything new is Kaizen.
There is Kaizen by selecting an existing use.
It is reasonable to learn, arrange and select the

Kaizen pattern faster.
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5. Kaizen of Functional Utilization
Improvements carried out by using existing features. To do
so, you must learn the features priorly.
Lost of data when the PC runs Add an auto-save features.
out of battery.
Working with some current stuff! 67

6. Kaizen of Auxiliary Tools
Auxiliary Tools:
　① Time 　 ② Stamp 　　③ Magnet 　　④ Glass
　⑤ Clip 　
Using auxiliary tools to make the job easier!
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7. The 3 Stages of The Application of
Auxiliary Tool
1. Current use:
100¥ Shop, obtaining something without delaying at the home
centre.
2. Betterment:
　　 To combine with the present condition and process the
commercial product.
3. Production:
　　 Combine and make use of the things that are already available.
Select and implement the better condition out of the constraints.

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8. Kaizen of Can Be Done by One Person
　 There were 2 persons in charged of the inspection of the ramp of
the car in an automotive repair shop: the one on the driver’s seat
and the one outside the car.

Examine the ramp by 2 persons. Place the mirrors in front of and the
back side of the car and make it
possible to examine the ramp alone.
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Attrition!
Kaizen- Thinking Guide
　　
Created on February 2011
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1. The Kaizen Spirit
1. Choose the creative choice of ‘If that is
not good, take this. If this is not good, take
that.’.
失敗
“The more you fail, the closer you are to success.”

　　　　　　　　　　　　　　　　　　　 Thomas Engine
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2. There is Kaizen if ‘Atarimae’ is
practiced.
1. Definition:
　 The definition of ‘Atarimae’ of boss and workers is different.
So, there is a reality of superiors are surprise with the sensible content at a glance.
Failure does not occur if Atarimae is practiced the way it should be.
Will there be various problems if Atarimae is not practicing for some reason?
There is a majority that does not practice Atarimae even when a big problem
happened in the market.
　　 It’s Atarimae!
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３．『一流企業はアタリマエの事を
　　　　　　　アタリマエにやっている』
１．一流
１．一流企業： (Top company):
　アタリマエの事をしてない時に即時、 Kaizen し実行できる風土がある。
なにも特殊なことをしているわけではない。
なにも特殊なこ
　
『契約した内容』を間違えなく、遅れなく実施しているだけである。
ルール通りに実施する事である。
２．．三
．三流企業： (Third class company)
駄目な会社はアタリマエの事をしてない事に気がつかない。
またに気がついてもそれをアタリマエにしない。
よってアタリマエの事ができず、つまらない間違い
、トラブルが頻発する。
　　
Follow the rules!! 74

　　　　　　　　　　　　　　　　　　
4. Changes of Proper Criteria
Innovation
　　 50 years ago 　　　　　　　 20 years ago 　　　　　　　　　　　
　　　　　　 Now
Social environment, social affairs, innovation and everything is constantly changing. Satisfy with the current conditions and it can no longer response to the
changing that have been vacant even the matter of course.
Not satisfied with the status quo, improve the case every day!

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5. Kaizen Report
Did something foolish. Improved the foolish thing.
Manifestation of the problem.

Face up to reality
Communization of the problem.
Without facing the reality and without doing anything, theory is being widespread.
76
8. Present Kaizen
Utilization of The Internet
1. Mailing list ：
A structure of e-mail delivery to multiple people simultaneously (multi-destination delivery) .
2. Video chat: 　
Real time image through voice chat and implemented transmission function webcam.
3. SNS (Social Network Service) :
The community-based subscription services defined as the promotion and supporting of the
connection of people. Alternatively, it may also provided service like websites such as Facebook,
Mixe, QQ etc.
4. BBS (Bulletin Board System) :
The mechanism is provided so that you can use the network environment, write articles, browse and
comment.
5. Online file storage service:
The users are renting disk space on the server machine. With the allocated disk space, the
user will be able to read and write freely over the internet.
6. Knowledge community:
The members answer questions of each other. It is called The Q&A Site and it resolves questions.
Some of the examples are Yahoo 知恵袋 , 技術の森 etc.
　　　　　 Utilize the free IT services and plan Kaizen. 77

8. Present Kaizen
Application of Mailing List
1. Definition of mailing list:
E-mail delivery to multiple people simultaneously(broadcast) mechanism. Abbreviated
as ML. As for services, they are often used to exchange information when a group is
interested in a particular topic.
2. Sample reference: Yahoo Group

Yahoo is running a free mailing list.
Share information and tasks with all the members.

78
8. Present Kaizen
Utilization of Video Chat
1. Definition: Video chat
The webcam is an implementation of real time image transmission in a voice chat.
Free TV conference and the image can be shared.
2. Sample reference: Skype （ Member: 　 5.6million people 　 Year 2010)
Group video Advantage of screen sharing

Colleagues around the world not only can build close Content that is hard to explain in words can actually be
relationships with customers and clients, working can shown. The screen of a presentation can be shared under
also be more efficient if group video call is being used. the control over one’s side and one can be taught on the
screen during a call.
Free TV conference and the image can be shared. 79

8. Present Kaizen
Utilization of SNS
1. Definition:
The promotion and supportiveness of the connections between people are defined as community-
based subscription service.
2. Sample reference: Facebook
Real Name Registration:
There is a trust in close interaction with
acquaintances in reality via real-name
　 registration.
Benefits of images and video-sharing:

The group can share images and videos.
Utilization of limited group

It is okay to exchange information within a limited group.
Information sharing between people and people who are utilizing IT. 80

8. Present Kaizen
Utilization of Forum
1. Definition:
The mechanism is provided so that you can use the network environment, write articles, browse
and comment.
2. Sample reference: Yahoo forum
Public information bulletin is available on IT. 81

8. Present Kaizen
Utilization of Online Storage Service
1. Definition:
Service users are lending disk space on the server machine. With the allocated
disk space, users are able to read and write freely over the Internet.
2. Sample reference: Google Document
One can manage and edit the data

wherever if he is connected to the IT.
Sample reference: Baidu 　文庫
Instant data sharing. 82

8. Present Kaizen
Utilization of Knowledge Community
1. Definition:
　 There is a website which fellow members answer questions to solve each other’s problem . It is
called the Q&A site.
2. Sample reference: 技術の森　 http://mori.nc-net
Technology manufacturing site Q&A
　　　　 Sample reference: Baidu 　百度　知道

Chinese Q&A site
Net questions and answers. 83

9. Current Kaizen Issues
1. Personnel training:
　　 Kaizen has been reduced by an increase in the power of temporary workers in the field. To
those who work in a short period, it is not the benefits to themselves. Kaizen is in the state
of no progression because there is no problem in the work remains to be said. Because the
work of maintaining the status quo getting more and more, managing become more
troublesome as well as the increasing of temporary workers in moving in the direction of
ensuring the apparent benefits.
2. Sharing:
When there are 2 temporary agencies in the factory, the Kaizen of a different temporary
agency and the process of another temporary agency are not reflected, at all. Although they
are on the same line, the production methods for each temporary agency are different.
3. Strategy and Tactics:

It is impossible for Kaizen to be the strategy. This is because there are activities until the
end at the field site… Currently, even overseas, the skills they are using at the field site has
been improved. The continuous winning of the global competition of the field site’s Kaizen
only, has become difficult from now on. The public and private sectors planned a
strategy together to focus on the future of long-term manufacturing of TOP management
and the implementation is an urgent.
　
Manufacturing is eternal as long as people improve. 84
Reference
Case
Art of War
According to Sun Tzu, the 5 following points are the 5 factors to compare
道
one’s friend or foe. (Tao)
• Moral Ethnics (Tao) - Ways to strengthen unity and political 天地
rulers and the people. (Tian) (Di)
• Heaven (Tian) - Changes in the weather, seasons,
temperature, etc.
• Terrain or Ground(Di) – Geographical features 将法
• Leadership or Commands ( Jiang) - Competence of the war leader. (Jiang) (Fa)
• Methods and Discipline (Fa) - Military regulations of the army system.
To be more specific, judge according to the following ‘Seven Stratagems’.

1. Which of the two sovereigns is imbued with the moral ethnics?
2. Which of the two generals has the most ability?
3. With whom lie the advantages derived from heaven?
4. On which side is discipline most rigorously enforced?
5. Which army is stronger?
6. On which side are officers and men more highly trained?
7. In which army is there the greater constancy both in reward and punishment?
Compared to the above pre-war elements, soldiers must be raised when a an adequate chance of success
is expected.
Revitalizing the techniques by understanding the human mind! 85

Reference The Ethics of Confucius
Case
There were four things which the master taught:
Letters, ethnics, devotion of soul and truthfulness .
Learn the letters and implement what one has learnt, devote the
implementation with truthfulness and have faith in what one is doing.
- Letters is the knowledge one gains from books.

Ethnics
- Ethnics is implementation.
Letters
- The devotion of soul is one devotes
something with sincerity.
Devotion of
- Truthfulness is one keeps promises and soul
gained trust from others. Truthfulness
Learning, implementing, doing things with sincerity and credibility is important.

86
‘There is no such thing, the God is
watching!’
　　 Peter Drucker 　‘ From The Origin of The
Professional’ 　　
87
参考文献
参考文献出版社著作者
改善基礎講座産業能率大学東沢文二
ＫＡＩＺＥＮ講談社今井正明
クリエイティブ・チョイス日本実業出版社堀内浩二
改善リーダー養成講座日刊工業新聞社山田日登志
トヨタ生産方式の実践哲学日刊工業新聞社山田日登志
プロフェッショナルの原点ダイヤモンド社 P.F. ドラッカー
88

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Kaizen Basic

Improvement is often described as Kaizen nowadays. When the expansion of Japanese

In order to improve current facilities, quality of the machine and productivity,

2. By making modifications on their own to suppress large-scale investment rather

1. Sakichi Toyoda ・・・ ‘ Automation with A Human Touch’

2. Kiichiro Toyoda ・・・ Just-in-time (J.I.T)

3. Taiichi Ohno ・・・ Systemization of the production of Toyata

Toyata is the first to incorporate and utilize the wisdom of the workers

‘Automation with A Human

Install a device to stop the machine to

• Persist in on-the-spot decision-

“ The sincerity and humanity itself is impossible without incident.

1. The origin of ‘one piece flow’

5. Do not make it so fast.

2. It brings confusions to customers if

3. “Automation with a Human Touch” is not

4. Keep asking the question ‘Why?’ even for 5 or

4. Muda of waiting 5. Muda of repair/rejects 6. Muda of transport

"In a company when there is no race to get each

At first, explore the changes that are under the constraints.

Therefore, the first thing we need to do is to take action of the changes.

Countermeasure 1: Wear a coat. Select the BEST option

The probability of successful is low, the thing no one wants to do,

Then try to verify why failures occurred.

Never give up and key to success is in it.

“Our greatest weakness lies in giving up. The most certain

A task is defined as a work to achieve a given objective. While Kaizen is

2) Management: Make an approachment and a mechanism to keep the

3) Cogitation ： Explain and make the employees consent to the definition of

Organization is set up in order to continue the promotion system at the field level.

Employees’ opinions, enthusiasm and education are necessary.

2. Do not waste time:

3. Do not spend money:

4. Suggestion from others:

Invention of light bulb, print technology, airplane…

Invention of internet, e-mail, Messenger…

Kaizen is a system, there is no point in learning techniques

Change A constant slow Sudden & explosive

Ideal Innovation Pattern

“The organization or the system is an organization (or a system) that is to be

Ideal innovation pattern Loss

In order to reduce loss management, QC management and facilities

Ideal innovation pattern

Kaizen is the better way to explore under restriction limits.

Also, write down notes of Kaizen and doing recording is important.

Kaizen = Reality measures

1. Record the carried out Kaizen activity.

Start with the recorded and datalysed work.

1. Contact the other departments related to the implementation,

Discuss with friends & ‘Databaselized’, education

Survey about IT & Provides information to other

Overhead wires stretched diagonally in order to reduce the wear of

• Does not take time.

There are ways to achieve various objectives

2. Eliminate the unnecessary works to improve.

3. Focus on the primarily necessary work.

4. Attempt to improve the productivity and quality.

Firstly, eliminate the unnecessary work at the beginning!

『 Reduce 』 : Abolition ⇒ Reduce

Learn the standards of Kaizen and practice them

Tools are hard to find

There are only 2 problems: 『 No 』 and 『 Hard to~ 』 .

Tools are easy to find

　　 1. Sakichi Toyoda ・・・ ‘ Automation with A Human Touch’

　　　 2. Kiichiro Toyoda ・・・ Just-in-time (J.I.T)

　　　 3. Taiichi Ohno ・・・ Systemization of the production of Toyata

　　　　　 “ The sincerity and humanity itself is impossible without incident.

　　 1. The origin of ‘one piece flow’

　　 5. Do not make it so fast.

　 Then try to verify why failures occurred.

There are only 2 problems: 『 No 』　 and 『 Hard to~ 』 .

Each participants create a Kaizen education plan. 　

　　　　　 Utilize the free IT services and plan Kaizen. 77

2. Sample reference: Skype （ Member: 　 5.6million people 　 Year 2010)

Sample reference: Baidu 　文庫

　　　　 Sample reference: Baidu 　百度　知道